High voltage component package



J. W. GAW

HIGH VOLTAGE COMPONENT PACKAGE Sept. 17, 1968 2 Sheets-Sheet 1 FiledMarch 16, 1967 5O KVDC Sept. 17, 1968 J. w.,GA'w

HIGH VOLTAGE COMPONENT PACKAGE 2 Sheets-Sheet 2 Filed March 16, 1967United States Patent T 3,402,380 HIGH VOLTAGE COMPONENT PACKAGE JohnWilliam Gaw, Elizabethtown, Pa., assiguor to AMP Incorporated,Harrisburg, Pa. Filed Mar. 16, 1967, Scr. No. 623,601 9 Claims. (Cl.339-89) ABSTRACT OF THE DISCLOSURE To provide a quick connect-disconnectand component replacement unit for high voltage circuits, conductivepaths are encapsulated within an insulating block having a plurality ofdeep sockets. Each socket contains a contact member connected to a pathas an output from a common input through a further contact member in ablock receptacle supplied by a high voltage connector and input lead.Each output includes a removable plug member containing encapsulatedsurge resistors. The plug members are of a configuration tosubstantially fill a block socket and each plug member includes acontact mateable with the socket contact member at one end and a socketat the other end adapted to receive a high voltage connector and outputlead.

Background of invention The usual approach to eliminating coronadischarge in high voltage circuits is to cover over all conductive pathsso as to eliminate the presence of a corona supporting medium such asair. Typical high voltage leads are for this reason comprised of a thickcovering of a corona resistant insulating material bonded to aconductive core. High voltage connectors are designed to exclude airfrom the mating conductive portions by providing intermating coronaresistant insulating material driven in compression to surround theconductive portions. High voltage components are embedded orencapsulated in corona resistant material with connectors alsoencapsulated in the same package.

This latter practice has made component replacement expensive in thatthe associated connectors are replaced each time any component in thepackage is replaced. -It has also made replacement of componentsdifficult and not available to field services. With many types ofequipment such as airborne, shipborne or vehicular radar, voltagevariation is expected and surge resistors are employed in each highvoltage supply. One example is in a cathode ray tube supply whereinthree cathode ray tubes are supplied in parallel from a single 50 k.v.DC source. The 10K surge resistors employed in series with each tubehigh voltage circuit may be expected to fail or deteriorate to a pointof required replacement rather frequently. Heretofore, replacement hastaken considerable time and has required removal of the supply circuitchassis. The importance of this problem can be visualized by assumingthat surge resistor failure occurs during a landing approach of anaircraft either using radar or being guided by the use of ground placedradar.

Summary of invention The present invention relates to a high voltagecorona resistant connector and component assembly which features quickconnect-disconnect and component replacement for high voltage circuits.One object is to provide a compact and inexpensive solution to theproblem of replacing high voltage components such as surge resistors,quickly and safely. Another object is to provide a high voltagetermination block, permitting replacement of high voltage componentsconnected in common to input and/ or output leads. Still another objectis to provide a corona resistant component, multiple connector assemblywith all conductive paths sealed and surrounded by solid dielectricmaterial. A further object is to provide a surge resistor connectorblock of a construction rugged enough for high voltage use in an adverseenvironment including vibration, moisture or high altitude.

The invention includes a block member of dielectric and insulatingmaterial having an input and a plurality of parallel output leadsencapsulated therein. A high voltage connector receptacle is mounted inthe block carrying a contact member connected to the input path andadapted to receive a high voltage connector and input lead. The paralleloutput leads in the block are connected to contact members at the bottomof relatively deep sockets formed in the block material. A plug memberis provided for each socket and is made to substantially fill the volumeof the socket. Each plug member contains a surge resistance encapsulatedwithin the plug and connected at each end to a further contact member.One contact member is mateable with the socket contact member and theother is positioned within a plug socket and mateable with a highvoltage connector and output lead.

In the drawings:

In FIGURE 1 is a schematic diagram in partial perspective showing theinvention assembly relative to an exemplary voltage supply and load; and

FIGURE 2 is an elevation of the invention assembly shown in FIGURE 1,partially sectioned to reveal details of the structure.

Component description Referring now to FIGURE 1, the invention assemblyshown as 10 serves as a distribution network for a high voltage supply12. The supply is connected to 10 by a high voltage lead 14 terminatedat each end by a high voltage connector, connectors 16 and 18. The inputto 10 is connected through parallel circuit paths therein each includinga 10K surge resistor. Parallel outputs from 10 are connected to threecathode ray tubes 20' via high voltage connectors 24 connected to leads22. These serve as the high voltage supply for the tubes 20.

As shown in FIGURE 2, the unit 10 is comprised of a block 20 of plasticmaterial. A material of high insulating and dielectric strength such asepoxy is preferred. The block is poured in a mold and placed undervacuum to remove all air. The block is provided with means such as holes32 which facilitate mounting of the block in or near the equipmentchassis served by the unit. Embedded within 30 is a conductive pathcomprised of a heavy wire lead 34. The lead is connected to a conductivepin 40 at a point well within the body of 30. The pin 40 is centeredwith an epoxy receptacle 38 which is half of the high voltage connector18. The connector 18 preferably has a configuration like that disclosedin. U.S. Patent No. 2,958,844 to W. A. Smith et al. granted Nov. 1,1960'.

The lead wire 34 is also connected to contact pin members 42 eachmounted at the bottom of a socket 43 in an epoxy disk 48 with a sleeve44 bonded to the material of 30. Each sleeve 44 includes at the top endan internal threading 46 which mates within the threading of a plug 50.The lower end of 44 is: relieved as at 49 to overlap 48.

Each plug 50 includes an outer epoxy shell 51. Each plug shell includesat the top a flange 52 which overlies and engages the entry of thesleeve 44 and the surrounding surface of the material of 30. The outersurface of 53 defines a series of flats 53 to facilitate manualinsertion and removal of 50 from the block. On each side of 52 the plugshell includes threading as at 54 and 56 which serves to secure the plugwithin the sleeve 44 and to secure a high voltage connector within theplug.

Each plug has an outer diameter and length to substantially fill thevolume of a sleeve 44 when the plug is seated therewithin. The slightspacing between the shell 51 and sleeve 44 is provided to facilitatemovement of 50 as it is inserted to permit mounting with pin 42. A bore55 which extends through the plug is dimensioned at the top portion toreceive the insulating body of a lead 22 in a close fit. This topportion is of a length to carry the lead well down inside of the blockwhen the plug is mounted therein. The lower portion of bore 55 isslightly enlarged as at 58 to receive an epoxy disk 60 carrying acontact pin 62 having a portion extending coaxially within the upperportion of bore 55 for engagement with a contact member connected to thelead 22. The lower portion of 62 is connected to a lead 64 of a resistor66 in turn connected by a lead and connector member 68 to a furtherresistor. The three resistors shown provide a series resistance path toa further contact member 70 secured with an epoxy sleeve 72 in thebottom of bore 55. The contact member 70 is in a receptacleconfiguration to mate with pin 42 fixed in the bottom of the socket. Theinterior of sleeve 72 is shaped to permit spring action of 70 andincludes a tapered opening 74 to aid proper mating of the contactmembers upon insertion of a plug within a socket,

In an actual embodiment the various resistors 66 were first joinedtogether with the outboard leads crimped to the contact members 62 and70 with the member 70 having the sleeve 72 secured thereover and themember 62 having the disk 60 thereon. The assembly of parts was thenpositioned within 55 and potted by flowing a potting material 76 throughan aperture 78 in the wall of s until the volume between 60 and 72 wasentirely filled. The potting material used was Silastic, a siliconerubber sufiiciently resilient and heat accommodating to avoid damagingresistors 66 during circuit use.

The high voltage connector 24 for use with the plugs 50 includes acontact member 80 secured to the lead wire of 22 within a continuousportion of the lead insulation in the matter taught in US. Patent No.3,163,692. Surrounding the lead is an epoxy nut 82 internally threatedto mate with the threading 56. Within nut 82 is a silicone rubber O-ring84 dimensioned to be compressed axially and expanded radially to sealagainst the outside surface of the lead and inside surface of the nut.

With a plug 50 installed and with the connector 24 secured therein in anactual embodiment, the surface path length from 80 to the outside of 30was approximately 3". The surface path length from 49 to the outside of30 was approximately 7". With three K resistors 66 the assembled unitwithstood a 65 K.V. DC hi-pot test (at sea level) without breakdown. Theunit operated satisfactorily over a temperature range from -550 C. to+125 C. The foregoing operation was achieved with the plugs manuallyinserted without the use of tools with an entire output connectiontaking only a minute or so. The unit was found to be vibration and shockresistant and be adequately sealed against moisture and contamination.

Having now described my invention in terms intended to enable apreferred mode of practice thereof, I define it through the appendedclaims.

I claim:

1. In a device for connecting high voltage circuit components into ahigh voltage circuit, a high voltage connector and input lead, a highvoltage connector and output lead, a block of insulating and dielectricmaterial including a conductive path embedded therein and connected tosaid input lead, and at least one relatively deep socket extendingtherewithin with a contact member at the bottom of said socket connectedto said path, a plug member of a size to fit within said socketsubstantially filling the volume thereof, said plug member having acomponent embedded in a dielectric and insulating material with meanstherein to connect said component to 4 said contact member and means toconnect said component to said high voltage connector and output lead.

2. The device of claim 1 wherein said plug is comprised of a shell ofrelatively hard dielectric and insulating material having a bore thereinwith said component fitted therein, connected to contact members andembedded in a resilient dielectric and insulating material filling aportion of said bore.

3. The device of claim 1 wherein said plug is comprised of a shellincluding a bore with a contact member secured well down within saidbore and engageable with a contact member on said high voltage connectorand lead.

4. The device of claim 1 wherein said socket and plug includeintermating surfaces operable when intermated to hold said plug againstaxial displacement relative to said block.

5. The device of claim 4 wherein said plug includes a radial and annularflange extending to contact the surface of said block when said plug isheld within said socket whereby to seal the space between said socketand said plug.

6. A quick connect-disconnect component assembly for high voltage useincluding a block member formed of material of high dielectric strength,an input-output path embedded therein connected at one end to a highvoltage connector receptacle and at the other end of a contact memberpositioned at the bottom of a socket formed in said block, a removableplug dimensioned to substantially fill said socket when inserted thereinand means to hold said plug within said socket during use of saidassembly, said plug including circuit components therewithin sealed by amaterial of high dielectric strength and including at each end a contactmember, one mateable with the contact member at the bottom of the socketand the other mateable with a contact member carried by a high voltageconnector and lead to connect said components on a high voltage circuit.

7. The assembly of claim 6 wherein said plug includes a socketcontaining the said other contact member positioned well within saidblock when said plug is inserted within the block socket.

8. In a device for providing a corona resistant connection of electricalcomponents in a high voltage circuit, a plug member having a centralbore containing a component therein embedded in an insulating anddielectric material, a first contact member at one end of said plug anda second contact member positioned Within said bore in said plug at apoint substantially removed from the other plug end, the said contactmembers being connected to said component, a block of insulating anddielectric material including a socket of substantial length relative tothe maximum exterior dimension of the block, a conductive path embeddedin said block connected to a third contact member extending into saidsocket and connected to fourth contact member of a high voltageconnector receptacle embedded in said block with an end exposed formating with a first high voltage connector and lead, the said plugmember being of a configuration to fit within said socket with thesecond contact member positioned well within the said block and mateablewith a second high voltage connector and lead having a fifth contactmember inserted within said plug bore to engage said second contactmember.

9. In a device for high voltage use in input path and at least oneoutput path embedded within a block of insulating material, the inputpath being connected to a high voltage receptacle mateable with a highvoltage connector and lead, the output path being connected to a contactmember at the bottom of a socket extended well within the body of saidblock, a removable plug member having a configuration to fit within saidsocket and substantially fill the volume thereof in an operativeposition, securing means to secure said plug within said socket againstdisplacement therefrom during device op- 5 6 eration, said plugincluding a component carried therein References Cited and sealedtherein by a solid insulating material, said UNITED STATES PATENTScomponent being connected to a contact member at each end, one plugcontact member being mateable with the 4/1942 Machlett et contact memberin said socket and the other being mate- 5 2911683 11/1959 Palermo fita1 18-: able with a high voltage connector connected to an out- FOREIGNPATENTS put lead, the said plug member including a bore extendingtherewith to receive a portion of said input lead 1,135,542 8/1962Germany' whereby said other contact member is connected thereto is wellwithin said block when said plug member is in an 10 MARVIN CHAMPIONPnmm'y Exammer' operative position. V J. H. McGLYNN, Assistant Examiner.

